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Re-use of used and scrapped tools was attempted adopting a centrifugal casting method to develop turning tools. These developed tools were employed for mild steel (A36) turning to examine the form stability of the tool at different cutting velocities in terms of the tool wear and chip formation. The cutting velocity was seen to have a definite effect on the form stability of the developed tool. The chip reduction coefficient decreased up to a cutting velocity of 50 m/min with a consequent effective increase in the shear angle. Beyond 50 m/min, at 60 m/min cutting velocity, the shear angle drastically decreased and cutting temperature increased as evidenced from the burnt chips generated. However, in the range of 30–50 m/min cutting velocity, the friction angle, chip flow velocity and shear velocity continued to increase with an increase of the cutting velocity. These results were seen to be very close to those obtained when the turning operation was carried out using a conventional cast (HSS M2) tool. The results, thus, showed, the developed tool can be best used for turning operations up to a cutting velocity of 50 m/min. This paves the way for re-using the tools scrapped after prolonged use.

Performance analysis of turning tool produced from scrap HSS cutting tools based on tool wear and chip formation